Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87) .
- Engine Oil and Oil Filter - Remove and DISCARD - Engine Oil and Oil Filter Replacement
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (KL9)
Plenum Front Panel Outer Reinforcement (1) - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
Air Cleaner Outlet Duct Bracket Bolt (1) - Remove
- Remove engine wiring harness from air cleaner outlet duct bracket.
Positive Crankcase Ventilation Fresh Air Tube (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (2) - Loosen [ 2x ]
- Air Cleaner Outlet Duct (3) - Remove
Disconnect the mass airflow sensor electrical connector (2) and remove all engine wiring harnesses from the air cleaner assembly.
Air Cleaner Nut (2) - Remove
Hood Latch Actuator Bolt (1) - Remove [ 2x ]
- Hood Secondary Latch Release Handle (2) - Remove
Intake Air Baffle Retainer (1) - Remove [ 9x ]
- Intake Air Splash Shield (2) - Remove
Intake Air Duct Retainer (1) - Remove
Air Cleaner Assembly (1) - Remove
- Front Wheelhouse Liner- Left Side - Remove Front Wheelhouse Liner Replacement
Disconnect the heated oxygen sensor electrical connector.
- The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
- Remove the heated oxygen sensor (1) using a suitable tool.
Exhaust Heat Shield Bolt- Left Side (1) - Remove
- Exhaust Front Pipe Heat Shield- Left Side (2) - Remove
Exhaust Front Pipe Nut- Left Side (1) - Remove [ 3x ]
- Lower the vehicle.
Mid Intermediate Steering Shaft Bolt (1) - Remove
Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft - Separate
- NOTE:
Pull only on the spark plug wire boot to remove the wire.
Spark Plug Wire- Left Side (1) @ Gas Engine Ignition Spark Plug (2) - Remove and position aside [ 4x ]
Remove the 3 left side exhaust manifold heat shield bolts (1) through the wheel opening.
Exhaust Manifold Heat Shield- Left Side (1) - Remove
Exhaust Manifold Bolt (1) - Remove and DISCARD [ 5x ]
Exhaust Manifold- Left Side (1) - Remove
- Exhaust Manifold Gasket (2) - Remove and DISCARD
Exhaust System Seal (1) - Remove and DISCARD
- NOTE:
Some components not shown for graphic clarity.
Positive Crankcase Ventilation Tube Connector (1) @ Positive Crankcase Ventilation Fitting - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Foul Air Tube (3) - Remove
- NOTE:
- The accessory drive primary belt is not reusable.
- Some components not shown for graphic clarity.
Using a suitable tool, cut the accessory drive primary belt (1).
- Accessory Drive Primary Belt (1) - Remove and DISCARD
Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (2) from the 3 valve rocker arm cover insulator retainers (1).
- Valve Rocker Arm Cover Insulator (3) - Remove
- Inspect the 3 upper intake manifold sight shield grommets (2) on the valve rocker arm cover insulator and replace as necessary.
Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Disengage - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Remove and position aside
Engine Wiring Harness Connector (1) @ Throttle Body - Disconnect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Remove [ 2x ]
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Disconnect
- Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Disconnect
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 4x ]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 3x ]
- NOTE:
Some components not shown for graphic clarity.
Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
- Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 3x ]
- NOTE:
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
Remove the intake manifold and intake manifold cover (1) as an assembly.
- Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
Intake Manifold Gasket (1) - Remove and DISCARD [ 8x ]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
WARNING:Refer to Safety Glasses Warning
Fuel Pump Insulator (1) - Remove
Fuel Feed Pipe (1) - Disconnect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (1) - Reposition
Fuel Feed Pipe Bolt (1) - Remove
- Fuel Feed Pipe (2) - Disconnect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (2) - Reposition
- CAUTION:
Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.
NOTE:Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) - Loosen until disengaged [ 2x ]
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) - Loosen until disengaged [ 2x ]
- Fuel Feed Pipe Bolt (2) - Remove
- Fuel Feed Intermediate Pipe (3) - Remove and DISCARD
- Disconnect fuel injection fuel rail connectors as needed.
Valve Rocker Arm Oil Control Valve Extension Harness (1) @ Valve Rocker Arm Oil Control Valve Harness - Disconnect
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness Bolt (1) - Remove [ 2x ]
Wiring Harness Retainer (1) - Remove
Engine Wiring Harness Bracket Bolt (1) - Remove
- Engine Wiring Harness - Reposition
- Engine Wiring Harness Connector @ Ignition Coil - Disconnect [ 4x ]
Valve Rocker Arm Cover Bolt (1) - Loosen until disengaged [ 9x ]
- Valve Rocker Arm Cover- Left Side (2) - Remove
Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) - Remove and DISCARD
- NOTE:
- Only replace the valve rocker arms and valve push rods as required.
- The rocker arm pivot support bolts are not serviced separately.
- Place the valve rocker arms and valve push rods in a rack so they can be installed in the same location from which they were removed.
Valve Rocker Arm Pivot Support Bolt (2) - Loosen until disengaged [ 8x ]
- Valve Rocker Arm (1) - Remove [ 8x ]
Valve Push Rod (1) - Remove [ 8x ]
Engine Wiring Harness Ground Bolt (1) - Remove
- Engine Wiring Harness (2) - Remove
- CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
NOTE:The forward most fastener on the Left Side Cylinder Head is unique to all other cylinder head fasteners. It is shorter, has an internal hex drive and has a lower final tightening torque angle.
Cylinder Head Bolt M12 x 102 (1) - Remove and DISCARD
- Cylinder Head Bolt M12 x 134 (2) - Remove and DISCARD [ 9x ]
- CAUTION:
After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
Cylinder Head (2) - Remove
- Cylinder Head Gasket (1) - Remove and DISCARD
Belt Idler Pulley Bracket Bolt (1) - Remove [ 3x ]
- Remove the belt idler pulley and belt idler pulley bracket (2) as an assembly.
Remove the 4 gas engine ignition spark plugs (1) and place each gas engine ignition spark plug (1) in a tray marked with the corresponding cylinder numbers.
Clean the cylinder head around the fuel injectors on bank 1 of any dirt or buildup.
- Remove the 4 bank 1 fuel injection fuel rail bolts (1).
- NOTE:
- In some cases, the fuel injectors may be difficult to remove because of heavy carbon build-up or other factors. If the fuel injectors are difficult to remove, apply solvent to the base of the fuel injector bores, and allow adequate soaking time, to loosen the fuel injectors.
- The bank 1 fuel injection fuel rail and fuel injectors (2) are removed as an assembly.
Install 2 sets of EN-49248 Injector Rail Assembly Remover (1) on fuel injection fuel rail.
- Install one EN-49248 Injector Rail Assembly Remover (1) in each of the bank 1 fuel injection fuel rail bolt bores.
- Turn each EN-49248 Injector Rail Assembly Remover (1) an even amount to pull the fuel injection fuel rail bank 1 and fuel injectors out evenly.
- Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
- Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
- Simultaneously lift both ends of the bank 1 fuel injection fuel rail (2) and remove from the left side cylinder head.
Fuel Injector Nozzle Housing Seal (1) - Remove and DISCARD [ 8x ]
Fuel Injector Seal (1) - Remove and DISCARD [ 4x ]
Refer to Diesel/Gasoline Vapors Warning
Refer to Safety Glasses Warning
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
The 4 bank 1 fuel injection fuel rail bolts (1) are retained in the bank 1 fuel injection fuel rail (2) and may be difficult to remove.